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Honda 1989 Elite CH250 Service Manual

Table Of Contents

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Table of Contents

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Table of Contents

1
Contents
2
How to Use this Manual
3
Symbols
4
General Information
4
General Safety
4
Carbon Monoxide
4
Coolant
5
Model Identification
6
Specifications
13
Torque Values
15
Tools
16
Lubrication and Seal Points
17
Cable and Harness Routing
22
Emission Control Systems
24
Emission Control Information Labels
24
Vehicle Emission Control Information Update Label
24
Vacuum Hose Routing Diagramlabel
25
Frame/Body Panels/Exhaust System
26
Body Panels
26
Frame Cover Removal Chart
27
Handlebar Cover Removal/Installation
27
Front Upper Cover Assembly
27
Handlebar Front Cover Removal/Installation
27
Handlebar Upper Cover Removal/Installation
28
Front Inner Fender a Removal/Installation
28
Front Inner Fender B/Side Cover Removal/Installation
29
Air Outlet Removal/Installation
29
Front Inner Box Removal/Installation
29
Luggage Box Removal/Installation
30
Center Cover Removal/Installation
30
Body Protector Cover Removal/Installation
31
Body Cover Removal/Installation
31
Floor Panel Removal/Installation
31
Fuel Tank under Cover Removal/Installation
31
Fork Cover Removal/Installation
32
Rear Fender Removal/Installation
33
Exhaust System Removal/Installation
34
Fuel Tank Removal/Installation
36
Maintenance
37
Service Access Guide
37
Vehicle View
39
Maintenance Schedule
40
Air Cleaner
40
Spark Plug
40
Valve Clearance
41
Carburetor Idle Speed
41
Headlight Aim
41
Side Stand
42
Lubrication System
43
Lubrication System Diagram
44
Oil Pump Removal/Installation
45
Oil Pump Disassembly/Assembly
46
Right Crankcase Cover Disassembly/Assembly
47
Fuel System
48
Fuel System Troubleshooting
49
Air Cleaner Case Removal/Installation
50
Carburetor Removal/Installation
52
Carburetor Disassembly/Assembly
54
Purge Control Valve Inspection
55
Pilot Screw Adjustment
55
High Altitude Adjustment
57
Cooling System
58
Cooling System Flow Pattern
59
Coolant Draining
60
Radiator Removal/Installation
62
Radiator/Fan Motor Disassembly/Assembly
63
Water Pump Disassembly/Assembly
64
Water Pump Shaft Holder Removal/Installation
64
Mechanical Seal Replacement
66
Thermostat Removal/Installation
67
Engine Removal/Installation
70
Engine Hanger Bracket Disassembly/Assembly
71
Engine Hanger Bolt Removal/Installation
72
Cylinder Head/Cylinder/Piston Troubleshooting
73
Cylinder Head Cover Removal/Installation
74
Cylinder Head Cover Disassembly/Assembly
75
Cylinder Head Removal/Installation
76
Camshaft Installation
76
Cam Chain Tensioner Installation
77
Cylinder Head Disassembly/Assembly
78
Cylinder/Piston Removal/Installation
79
Crankcase/Crankshaft Troubleshooting
80
Crankcase Separation/Assembly
81
Drive Train Troubleshooting
82
Drive Belt Cover Removal/Installation
83
Drive Belt/Drive Pulley/Clutch/Driven Pulley Removal/Installation
84
Moveable Drive Face Nut Removal/Installation
84
Clutch Outer Removal/Installation
85
Moveable Drive Face Disassembly/Assembly
86
Clutch/Driven Pulley Disassembly/Assembly
87
Clutch Disassembly/Assembly
88
Final Reduction Removal/Installation
89
Drive Shaft Replacement
89
Bearing Replacement
90
Front Wheel/Suspension/Steering Troubleshooting
91
Throttle Houseing Removal/Installation
92
Handlebar Removal/Installation
93
Front Wheel Removal/Installation
94
Front Wheel Disassembly/Assembly
95
Front Shock Absorber Removal/Installation
96
Front Shock Absorber Disassembly/Assembly
97
Shock Absorber Lower Joint Removal
98
Steering Stem Removal/Installation
99
Ball Race Replacement
100
Rear Wheel/Suspension Troubleshooting
101
Swingarm/Rear Wheel Disassembly/Assembly
102
Rear Shock Absorber Removal/Installation
103
Shock Absorber Disassembly/Assembly
104
Upper Joint Removal/Installation
105
Brake System Troubleshooting
106
Front Brake Disassembly/Assembly
108
Rear Brake Disassembly/Assembly
109
Brake Pedal Removal/Installation
110
Parking Brake Removal/Installation
111
Parking Brake Adjustment
112
Charging System/Alternator
113
Charging System Diagram
114
Charging System Troubleshooting
115
Battery Removal/Installation
116
Charging System Inspection
116
Regulated Voltage/Charging Current Inspection
117
Regulator/Rectifier - Wire Harness Inspection
118
Alternator Inspection
118
Regulator/Rectifier - Unit Inspection
119
Ignition System
120
Ignition System Diagrams
121
Ignition System Troubleshooting
123
Ignition System Inspection
123
Ignition Coil
124
Pulse Generator Inspection
125
Ignition Timing
126
Pulse Generator and Alternator Removal/Installation
128
Flywheel Nut Removal
128
Flywheel Nut Installation
129
Electric Starter/Starter Clutch Troubleshooting
130
Starter Motor will Not Turn
131
Electric Starter/Starter Clutch Diagrams
132
Starter Motor Removal/Installation
133
Starter Motor Disassembly/Assembly
134
Starter Clutch Disassembly/Assembly
135
Starter Relay Switch Removal and Inspection
136
Lights/Meters/Switches
137
Lights/Meters/Switches Diagrams
138
Headlight Assembly Removal/Installation
139
Headlight Bulb Replacement
139
Front Turn Signal Light Bulb Replacement
139
Rear Turn Signal and Tail/Brake Light Bulb Replacement
140
Combination Meter Removal/Installation
141
Combination Meter Disassembly/Assembly
142
Brake Light Switch/Starter Limiter Switch
143
Fuel Level Sensor
144
Auto-Bystarter Inspection
144
Auto-Bystarter Removal
145
Side Stand Switch Inspection
145
Side Stand Switch Removal
146
Fan Motor Switch
146
Temperature Gauge
148
Wiring Diagram
149
Troubleshooting
149
Engine Does Not Start or Is Hard to Start
150
Engine Lacks Power
151
Poor Performance at Low and Idle Speeds
151
Poor Performance at High Speed
152
Engine Noise
153
Index

Troubleshooting

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